Last system for articles with braided components

ABSTRACT

A last system and a method of making the last system are disclosed. The last system includes a last member and an exterior layer. The exterior layer becomes deformable when heated above a characteristic temperature. The method can include forming a braided footwear component on the last system. The exterior layer may be joined with the braided footwear component by heating the last system above the characteristic temperature.

BACKGROUND

The present embodiments relate generally to articles of footwear, and inparticular to a last system for making articles of footwear.

Articles of footwear generally include two primary elements: an upperand a sole structure. The upper may be formed from a variety ofmaterials that are stitched or adhesively bonded together to form a voidwithin the footwear for comfortably and securely receiving a foot. Thesole structure is secured to a lower portion of the upper and isgenerally positioned between the foot and the ground. In many articlesof footwear, including athletic footwear styles, the sole structureoften incorporates an insole, a midsole, and an outsole.

An upper may be manufactured using a last. The last may be a foot-shapedform around which the upper may be assembled so that the upper has theapproximate shape of a foot.

SUMMARY

In one aspect, a method of making an upper for an article of footwearincludes providing a last member, where the last member has an outersurface. The method also includes forming an exterior layer of a heatdeformable material onto the outer surface of the last member. Themethod also includes forming a braided footwear component onto theexterior layer. The method also includes heating the exterior layer sothat the exterior layer is joined with the braided footwear component toform a composite structure. The method also includes removing the lastmember from the composite structure.

In another aspect, a method of making an upper for an article offootwear includes providing a last member, where the last member has anouter surface. The method also includes forming a first region of anexterior layer onto the outer surface of the last member, where thefirst region has a first thickness and where the exterior layer iscomprised of a heat deformable material. The method also includesforming a second region of the exterior layer onto the outer surface ofthe last member, where the second region has a second thickness that isdifferent from the first thickness. The method further includes forminga braided footwear component onto the exterior layer and heating theexterior layer so that the exterior layer is joined with the braidedfootwear component to form a composite structure. The method alsoincludes removing the last member from the composite structure.

In another aspect, a last system for making an article of footwearincludes a last member with an outer surface, where the last member hasa foot-like geometry. The last system also includes an exterior layerdisposed on the outer surface. The last member is made of a firstmaterial and the exterior layer is made of a second material that isdifferent than the first material. The second material of the exteriorlayer has a characteristic temperature, where the second material isconfigured to be moldable when heated to a temperature above thecharacteristic temperature. The exterior layer has a first region and asecond region, where the first region has a first thickness, and wherethe second region has a second thickness that is different than thefirst thickness.

Other systems, methods, features and advantages of the embodiments willbe, or will become, apparent to one of ordinary skill in the art uponexamination of the following figures and detailed description. It isintended that all such additional systems, methods, features andadvantages be included within this description and this summary, bewithin the scope of the embodiments, and be protected by the followingclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments can be better understood with reference to the followingdrawings and description. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principles of the embodiments. Moreover, in the figures, likereference numerals designate corresponding parts throughout thedifferent views.

FIG. 1 is a schematic view of an embodiment of a last system including alast member and an exterior layer;

FIG. 2 is a schematic view of an embodiment of a last system undergoingheating;

FIGS. 3-5 are schematic views of steps of forming a last member using anadditive manufacturing machine, according to an embodiment;

FIG. 6 is a schematic view of an embodiment of another method ofapplying an exterior layer to a last member;

FIGS. 7-8 are schematic views of steps of forming a braided footwearcomponent on a last system, according to an embodiment;

FIG. 9 is a schematic view of a last system after receiving a braidedfootwear component, including a step of removing a portion of thebraided footwear component, according to an embodiment;

FIGS. 10-11 are schematic views of a braided footwear component and anexterior layer being heated to form a composite structure, according toan embodiment;

FIG. 12 is a schematic view of a step of removing a last member from acomposite structure, according to an embodiment;

FIG. 13 is a schematic view of a finished article of footwear includinga composite structure and sole components, according to an embodiment;

FIG. 14 is a schematic view of an article of footwear being worn by auser, according to an embodiment;

FIG. 15 illustrates a possible configuration for strands in a compositestructure, according to a first embodiment;

FIG. 16 illustrates a possible configuration for strands in a compositestructure, according to a second embodiment;

FIG. 17 illustrates a possible configuration for strands in a compositestructure, according to a third embodiment;

FIG. 18 is a schematic view of a step in a process of making a lastsystem including regions of varying thickness, according to anembodiment;

FIG. 19 is a schematic view of an embodiment of a last system having anexterior layer with regions of varying thickness;

FIG. 20 is a schematic view of an embodiment of a composite structurehaving regions of varying thickness;

FIGS. 21-22 illustrate schematic views of the response of differentregions of a composite structure to applied forces; and

FIG. 23 is a schematic view of an embodiment of a last system includingan exterior layer with various different regions of varying thickness.

DETAILED DESCRIPTION

FIG. 1 illustrates an isometric view of an embodiment of a last system100. Last system 100 may have the approximate geometry of a foot, andmay generally be configured to receive materials for forming the upperof an article of footwear. In the exemplary embodiment, last system 100is shown with a general foot shape, however in other embodiments lastsystem 100 could be configured with any desired foot geometry.

Last system 100 can be used to manufacture components (e.g., an upper)of various kinds of footwear. The types of footwear may include, but arenot limited to: hiking boots, soccer shoes, football shoes, sneakers,running shoes, cross-training shoes, rugby shoes, basketball shoes,baseball shoes as well as other kinds of shoes. Moreover, in someembodiments, last system 100 may be used to manufacture various otherkinds of non-sports related footwear, including, but not limited to:slippers, sandals, high heeled footwear, and loafers.

Although the embodiment depicts a last system configured for makingarticles of footwear, other embodiments could use a last system formanufacturing other kinds of articles. Such articles may include, butare not limited to: articles of clothing, hats, gloves, socks, bags,pads, sporting equipment as well as any other kinds of articles that maybe manufactured using a last of some kind. In other embodiments, thegeometry of a last system could be varied to accommodate any other kindof article.

Last system 100 may further include a last member 102 and an exteriorlayer 104. In particular, as seen in FIG. 1, exterior layer 104 may bedisposed on outer surface 106 of last member 102. As seen in theenlarged cross-sectional view of FIG. 1, last member 102 may comprise acore portion, or interior portion, of last system 100. Specifically, inat least some embodiments, last member 102 may be completely covered byexterior layer 104. Alternatively, in some other embodiments, only someportions of last member 102 may be covered with exterior layer 104,while other portions of last member 102 may be exposed on an outermostsurface of last system 100.

For purposes of illustration, exterior layer 104 is depicted assubstantially transparent in the exemplary embodiments, so that lastmember 102 is at least partially visible through exterior layer 104. Insome embodiments, exterior layer 104 may be made of a material that isat least partially transparent. However, in other embodiments (notshown), exterior layer 104 may be substantially opaque such that lastmember 102 is not even partially visible through exterior layer 104.

Referring to FIG. 1, for purposes of reference, last system 100 may bedivided into forefoot portion 10, midfoot portion 12 and heel portion14. These portions may be generally associated with correspondingportions of a foot, since last system 100 shares an approximatelysimilar geometry with a foot. Forefoot portion 10 may be generallyassociated with the toes and joints connecting the metatarsals with thephalanges. Midfoot portion 12 may be generally associated with the archof a foot. Likewise, heel portion 14 may be generally associated withthe heel of a foot, including the calcaneus bone. In addition, lastsystem 100 may include lateral side 16 and medial side 18. Inparticular, lateral side 16 and medial side 18 may be opposing sides oflast system 100. Furthermore, both lateral side 16 and medial side 18may extend through forefoot portion 10, midfoot portion 12 and heelportion 14.

It will be understood that forefoot portion 10, midfoot portion 12 andheel portion 14 are only intended for purposes of description and arenot intended to demarcate precise regions of last system 100. Likewise,lateral side 16 and medial side 18 are intended to represent generallytwo sides of last system 100, rather than precisely demarcating lastsystem 100 into two halves. Moreover, throughout the embodiments,forefoot portion 10, midfoot portion 12, heel portion 14, lateral side16 and medial side 18 may be used to refer to portions/sides ofindividual components of last system 100, including last member 102and/or exterior layer 104.

For consistency and convenience, directional adjectives are employedthroughout this detailed description corresponding to the illustratedembodiments. The term “longitudinal” as used throughout this detaileddescription and in the claims refers to a direction extending a lengthof a component (e.g., a last system). In some cases, the longitudinaldirection may extend from a forefoot portion to a heel portion of thecomponent. Also, the term “lateral” as used throughout this detaileddescription and in the claims refers to a direction extending along awidth of a component. In other words, the lateral direction may extendbetween a medial side and a lateral side of a component. Furthermore,the term “vertical” as used throughout this detailed description and inthe claims refers to a direction generally perpendicular to a lateraland longitudinal direction. For example, the vertical direction of lastsystem 100 may generally extend from bottom side 110 of last system 100to top side 112 of last system 100. In addition, as used herein, theterms “outer” and “inner” (e.g., outer surface and inner surface orouter portion and inner portion) refer to related portions and/orsurfaces. The outer portion or outer surface of a component may bedisposed further from a reference interior location (e.g., a centralaxis, interior void, etc.) than the inner portion or surface of acomponent.

The geometry of last member 102 may vary in different embodiments. Insome embodiments, last member 102 may have the approximate geometry of afoot. Any of the geometries for footwear lasts known in the art could beused. Of course, in some other embodiments, last member 102 couldinclude other geometric features that do not correspond to a foot. Suchfeatures could include flanges, handles, openings, or other features.For example, some embodiments can include geometric features that allowa last to be mounted or otherwise attached to a machine, stand orfixture during the manufacturing process.

The dimensions of last member 102 may vary in different embodiments.Exemplary dimensions may include dimensions commonly associated withfootwear lasts, including ranges of dimensions for various differentshoes sizes. In some embodiments, for example, last member 102 may beassociated with a particular foot size, which may correspond with agiven range for the height, length and width.

The materials comprising last member 102 may vary in differentembodiments. Exemplary materials that may be used for last member 102include, but are not limited to: woods, metals, plastics, rubbers,composite materials as well as possibly other materials. In someembodiments, last member 102 could be made of a thermosetting polymer.In other embodiments, last member 102 could be made of a thermoplasticpolymer. It is contemplated that in at least some embodiments, lastmember 102 may be made of a material known for use in printingthree-dimensional objects, as discussed in further detail below.

The geometry of exterior layer 104 may vary in different embodiments. Insome embodiments, exterior layer 104 may comprise a relatively thinlayer of material formed on the outer surface 106 of last member 102.For example, in the exemplary embodiment, forefoot portion 10 of lastmember 102 may have a radial thickness 130 as measured from a centralaxis 132 to outer surface 106 of last member 102. In contrast, exteriorlayer 104 may have a thickness 140, as measured between an inner surface107 of exterior layer 104 and an outer surface 108 of exterior layer104. In some embodiments, thickness 130 may be substantially greaterthan thickness 140. In other words, at least some portions of lastmember 102 (e.g., a forefoot portion) may be substantially thicker thanexterior layer 104. In some cases, thickness 130 could be five to tentimes greater than thickness 140. In other cases, thickness 140 could beten to twenty times greater than thickness 140. As one example,thickness 130 could have a value of three to eight centimeters, whilethickness 140 may be on the order of one to ten millimeters.

In the embodiments shown in FIGS. 1-17, exterior layer 104 may have asubstantially constant thickness. However, in other embodiments,exterior layer 104 could have a thickness that varies over differentregions of last system 100. Embodiments with varying thicknesses for anexterior layer are discussed below and shown in FIGS. 18-23.

The material characteristics of last member 102 and exterior layer 104could vary. For example, in different embodiments, the relative rigidityand/or hardness of last member 102 and exterior layer 104 could vary.For purposes of comparison, last member 102 may be characterized by afirst rigidity and exterior layer 104 may be characterized by a secondrigidity. In some embodiments, the first rigidity may be greater thanthe second rigidity (e.g., last member 102 may be more rigid thanexterior layer 104). In other embodiments, the second rigidity may begreater than the first rigidity (e.g., exterior layer 104 may be morerigid than last member 102). In still other embodiments, the firstrigidity could be substantially equal to the second rigidity (e.g., lastmember 102 and exterior layer 104 may be equally rigid). In an exemplaryembodiment, exterior layer 104 may be less rigid than last member 102.

In different embodiments, exterior layer 104 could be made fromdifferent materials. In some embodiments, exterior layer 104 may be madeof a heat deformable material. The term “heat deformable material” asused throughout this detailed description and in the claims refers toany material that may become pliable, moldable or that may melt and/orflow when heated. Heat deformable materials could include thermosettingpolymers and thermoplastic polymers. In addition, heat deformablematerials could also include materials comprised of a combination ofthermosetting materials and thermoplastic materials, such as athermoplastic elastomer (TPE).

Heat deformable materials (e.g., thermosetting polymers andthermoplastic polymers) may be associated with a characteristictemperature. The term “characteristic temperature” as used throughoutthis detailed description and in the claims refers to a temperature atwhich one or more properties of a material changes. Such changes may ormay not include phase changes. In some cases, for example, thecharacteristic temperature may be associated with a glass transition ofa material, in which case there is no phase change in the material butthe material becomes more pliable and/or moldable. In such cases, thecharacteristic temperature may be associated with the glass-transitiontemperature of a material. In other cases, the characteristictemperature could be associated with a phase change, such as a changefrom a solid state to a liquid state (i.e., melting). In such cases, thecharacteristic temperature could be associated with a meltingtemperature of a material.

In some embodiments, exterior layer 104 may be made of one or morethermoplastic materials. Thermoplastic materials may become pliable ormoldable above a characteristic temperature and then return to a solidstate when cooled below the characteristic temperature. The value of thecharacteristic temperature may be determined according to the specificmaterials used. Exemplary thermoplastics that could be used for anexterior layer include, but are not limited to: acrylic, nylon,polyethylene, polypropylene, polystyrene, polyvinyl chloride (PVC) andthermoplastic polyurethane (TPU).

When made of different materials, last member 102 and exterior layer 104may have different melting temperatures and/or glass transitiontemperatures. In some embodiments, for example, last member 102 could bemade of a material with a relatively high glass transition temperatureand/or melting temperature. Alternatively, last member 102 may not havea glass transition temperature and/or melting temperature and insteadmay degrade (e.g., combust) above a characteristic temperature. Incontrast, exterior layer 104 may have a relatively low glass transitiontemperature and/or melting temperature. Thus, for example, if exteriorlayer 104 is associated with a characteristic temperature, which may beeither a glass transition temperature or a melting temperature, lastmember 102 may be configured to remain in a solid form at temperaturesexceeding the characteristic temperature. Such provisions may allowexterior layer 104 to become pliable and/or melt when last system 100 isheated above the characteristic temperature, while last member 102remains in a solid form to maintain the desired foot geometry.

FIG. 2 is a schematic view of last system 100 undergoing heating by aheat source 180. Heat source 180 could be any kind of heat source,including, but not limited to: a heating lamp, an electric heater, aflame as well as possibly any other kind of heat source known in theart. For purposes of clarity, heat source 180 is depicted as a singlesource, though other embodiments could include any other number of heatsources arranged in any configuration around a last system.

As seen in FIG. 2, heat source 180 raises the temperature of a portion190 last system 100 above a characteristic temperature (e.g., a glasstransition temperature and/or a melting temperature associated withexterior layer 104). Above this characteristic temperature, exteriorlayer 104 may become pliable and/or melt. Thus, as seen in the enlargedcross-sectional view, portion 190 has started to melt on outer surface106 of last member 102. Moreover, it is clear that last member 102retains its shape and does not deform even when heated above thecharacteristic temperature.

In different embodiments, heat source 180 may be configured to operatein a range of temperatures. In some embodiments, heat source 180 mayheat portions (or all) of last system 100 to a temperature approximatelyin the range between 100 and 200 degrees Celsius. In other embodiments,heat source 180 may heat portions (or all) of last system 100 to atemperature approximately in the range between 150 and 300 degreesCelsius. In still other embodiments, heat source 180 may heat portions(or all) of last system 100 to a temperature substantially greater than300 degrees Celsius. Moreover, in some other embodiments, heat source180 could heat portions (or all) of last system 100 to a temperatureless than 100 degrees Celsius. It will be understood that the operatingrange of heat source 180 may be selected according to the types ofmaterials used to make last system 100 (e.g., the materials comprisinglast member 102 and exterior layer 104), as well as possibly othermanufacturing considerations. Specifically, in some cases, the operatingrange of heat source 180 may be selected so that an exterior layer of alast system can be heated above a glass-transition temperature and/ormelting point, while remaining below a temperature at which a lastmember becomes pliable, melts and/or degrades.

Embodiments can include provisions for forming a last system using anadditive manufacturing process. In some embodiments, a last memberand/or an exterior layer could be built using an additive manufacturingprocess. In one embodiment, last member 102 and exterior layer 104 mayboth be built using an additive manufacturing process.

FIGS. 3-5 illustrate a schematic view of steps in a process formanufacturing last system 100 using an additive manufacturing device200. The term “additive manufacturing”, also referred to as“three-dimensional printing”, refers to any technology for making athree-dimensional object through an additive process where layers ofmaterial are successively laid down under the control of a computer.Exemplary additive manufacturing techniques that could be used include,but are not limited to: extrusion methods such as fused depositionmodeling (FDM), electron beam freeform fabrication (EBF), direct metallaser sintering (DMLS), electron-beam melting (EBM), selective lasermelting (SLM), selective heat sintering (SHS), selective laser sintering(SLS), plaster-based 3D printing, laminated object manufacturing (LOM),stereolithography (SLA) and digital light processing (DLP). In oneembodiment, additive manufacturing device 200 could be a fuseddeposition modeling type printer configured to print thermoplasticmaterials such as acrylonitrile butadiene styrene (ABS) or polyacticacid (PLA).

An example of a printing device using fused filament fabrication (FFF)is disclosed in Crump, U.S. Pat. No. 5,121,329, filed Oct. 30, 1989 andtitled “Apparatus and Method for Creating Three-Dimensional Objects,”which application is herein incorporated by reference and referred tohereafter as the “3D Objects” application. Embodiments of the presentdisclosure can make use of any of the systems, components, devices andmethods disclosed in the 3D Objects application.

Additive manufacturing device 200 may be used to manufacture one or morecomponents used in forming an article of footwear. For example, additivemanufacturing device 200 may be used to form a footwear last (or simply“last”), which may be used in forming an upper of an article offootwear. Additionally, in at least some embodiments, additivemanufacturing device 200 could be used to form other components for anarticle of footwear, including, but not limited to: sole components(e.g., insole components, midsole components and/or outsole components),trim components, overlay components, eye-stays, panels or other portionsfor an upper, as well as possibly other components. Such provisions mayutilize any of the systems and/or components disclosed in Sterman, U.S.Patent Publication Number 2015/0321418, now U.S. patent application Ser.No. 14/273,726, filed May 9, 2014, and titled “System and Method forForming Three-Dimensional Structures,” the entirety of this applicationbeing herein incorporated by reference.

As shown in FIGS. 3-4, additive manufacturing device 200 may include adevice housing 201, an actuating assembly 202 and extrusion head 205.Additive manufacturing device 200 may also include platform 206. In somecases, extrusion head 205 may be translated via actuating assembly 202on a z-axis (i.e., vertical axis), while platform 206 of additivemanufacturing device 200 may move in the x and y directions (i.e.,horizontal axis). In other cases, extrusion head 205 could have fullthree-dimensional movement (e.g., x-y-z movement) above a fixedplatform.

FIGS. 3-4 depict how customized last member 102 is formed using additivemanufacturing device 200. Specifically, last member 102 is formed asextrusion head 205 lays down successive layers of material. For example,FIG. 3 shows an initial layer 210 of last member 102 being formed. InFIG. 4, a final layer 212 of last member 102 has been formed.

In some embodiments, exterior layer 104 may also be formed with anadditive manufacturing process. As seen in FIG. 5, once last member 102has been formed, additive manufacturing device 200 may be used to formexterior layer 104 on last member 102. In the embodiment shown in FIG.5, a top portion 220 of exterior layer 104 has been formed (e.g.,printed) onto outer surface 106 of last member 102.

Although the exemplary embodiment depicts last member 102 beingcompletely formed before exterior layer 104 is added, in otherembodiments last member 102 and exterior layer 104 could be manufacturedsuch that some portions of exterior layer 104 are extruded before lastmember 102 has been completely formed. For example, in anotherembodiment, the forefoot portion of last member 102 and the associatedforefoot portions of exterior layer 104 may be formed before the midfootand/or heel portions of last member 102 (and exterior layer 104) areformed.

It will also be understood that in other embodiments last system 100 maybe formed in any other manner. For example, in one alternativeembodiment shown in FIG. 6, a last member 300 may be associated with acontainer 310 of moldable material 302 (e.g., a melted thermoplasticmaterial). Upon dipping a portion 304 of last member 300 into moldablematerial 302, portion 304 may be covered with a layer 320 of moldablematerial 302. Layer 320 may solidify to form a portion of an exteriorlayer on last member 300. Although only a portion of last member 300 iscovered in this example, it will be understood that such a method couldbe used to form an exterior layer over the entire exterior of lastmember 300. In still other embodiments, a material for forming anexterior layer could be sprayed onto last member 300 or otherwiseapplied with heat and/or pressure.

FIGS. 7-8 illustrate schematic views of a method of forming a braidedfootwear component onto last system 100 using a braiding device 400.Exemplary braiding devices could include any overbraiding devices,radial braiding devices and three-dimensional braiding devices. Braidingdevice 400 may be configured to apply tensile elements (e.g., threads)onto a last in order to form braided strands over the last. To this end,braiding device 400 may be configured with a plurality of spools 402that are arranged on a perimeter portion 404 of braiding device 400.Threads 406 from spools 402 may be fed radially inwards towards acentral braiding area 410.

The exemplary method provides a braided footwear component on a lastsystem. The term “braided footwear component” (or simply “braidedcomponent”) as used throughout this detailed description and in theclaims refers to any arrangement of tensile strands (e.g., threads,yarns, etc.) where some tensile strands are braided with others.Moreover, braiding as used herein refers to any arrangement where threeor more strands of material are intertwined.

In embodiments utilizing a braiding device for making an upper, thematerials used to manufacture the upper may primarily be comprised ofvarious kinds of tensile elements (or tensile strands) that can beformed into an upper using the braiding device. Such tensile elementscould include, but are not limited to: threads, yarns, strings, wires,cables as well as possibly other kinds of tensile elements. As usedherein, tensile elements may describe generally elongated materials withlengths much greater than corresponding diameters. In other words,tensile elements may be approximately one-dimensional elements, incontrast to sheets or layers of textile materials that may generally beapproximately two-dimensional (e.g., with thicknesses much less thantheir lengths and widths). The exemplary embodiment illustrates the useof various kinds of threads, however it will be understood that anyother kinds of tensile elements that are compatible with a braidingdevice could be used in other embodiments.

Exemplary threads or yarns that may be used with a braiding deviceinclude fibers made from materials including, but not limited to: wool,flax, and cotton, as well as other one-dimensional materials. The fibersmay be formed from animal, plant, mineral, and synthetic sources. Animalmaterial may include, for example, hair, animal fur, animal skin, silk,etc. Plant material may include, for example, grass, rush, hemp, sisal,etc. Mineral material may include, for example, basalt fiber, glassfiber, metal fiber, etc. Synthetic fibers may include, for example,polyester, aramid, acrylic, carbon fiber, as well as other syntheticmaterials.

In FIG. 7, the process of forming a braided footwear component onto lastsystem 100 may begin by associating last system 100 with braiding device400. In some cases, last system 100 may be aligned in a particularorientation with braiding device 400, such that a desired portion oflast system 100 is aligned with a central braiding area 410 of lastsystem 100.

In FIG. 8, last system 100 may be fed through central braiding area 410of braiding device 400 to form a braided footwear component in the formof a braided upper. In some embodiments, last system 100 may be manuallyfed through braiding device 400 by an operator. In other embodiments, acontinuous last feeding system can be used to feed last system 100through braiding device 400. The present embodiments could make use ofany of the methods and systems for forming a braided upper as disclosedin Bruce, U.S. Patent Publication Number 2015/0007451, now U.S. patentapplication Ser. No. 14/495,252, filed Sep. 24, 2014, and titled“Article of Footwear with Braided Upper,” the entirety of which isherein incorporated by reference. Moreover, some embodiments couldinclude additional provisions for holding and/or feeding articlesthrough the braiding device. For example, some embodiments may includesupport platforms, rails, conveyors or other structures that canfacilitate feeding articles through the braiding device.

As shown in FIG. 8, as last system 100 is fed through braiding device400, a braided footwear component 500 is formed around last member 102.Specifically, braided footwear component 500 is formed onto an outersurface of exterior layer 104 of last system 100. In this case, braidedfootwear component 500 comprises a continuously braided upper componentthat conforms to last system 100, and therefore has the approximategeometry of last system 100.

FIGS. 9-11 illustrate steps in a process of joining the strands of abraided footwear component with an exterior layer. As used herein,joining may refer to bonding, fusing, fixing or otherwise attachingstrands of a braided footwear component with the material comprising anexterior layer of a last system. Referring first to FIG. 9, afterremoving last system 100 with braided footwear component 500 frombraiding device 400, a portion 510 of braided footwear component 500 maybe removed. Specifically, in some cases, portion 510 may be adjacent toa cuff portion 512 of braided footwear component 500, which may createan opening 514 through which last member 102 can eventually be removed.

Initially, in the configuration shown in FIG. 9, strands 550 of braidedfootwear component 500 are disposed on outer surface 108 of exteriorlayer 104. In order to begin joining strands 550 and exterior layer 104,last system 100 may be heated using heat sources 600, as shown in FIGS.10 and 11. For purposes of clarity two heat sources are depicted inFIGS. 10 and 11, however in other embodiments any number of heat sourcescould be used. Moreover, heat sources 600 could be positioned at anylocation and/or orientation relative to last system 100. In some cases,heat sources 600 may be configured as part of a station on a conveyorsystem, so that last system 100 with braided footwear component 500 isautomatically moved near heat sources 600 after exiting braiding device400.

As seen in FIG. 10, exterior layer 104 may become pliable as thetemperature of exterior layer 104 is raised above a predeterminedtemperature (e.g., a characteristic temperature such as a glasstransition temperature or a melting temperature). Tension in braidedfootwear component 500 may tend to pull strands 550 into exterior layer104 (i.e., radially inward), which is now pliable and capable ofreceiving strands 550. Referring next to FIG. 11, the materialcomprising exterior layer 104 becomes pliable enough with continuedheating to further mold around strands 550. This allows the material ofexterior layer 104 to fill in the spaces between strands 550, therebypartially (or fully) encasing strands 550.

After braided footwear component 500 and exterior layer 104 have beenjoined or otherwise integrated together, heat sources 600 may beremoved. In some cases, braided footwear component 500 and the materialcomprising exterior layer 104 may be cooled below the predeterminedtemperature so that the material comprising exterior layer 104 forms asubstantially solid material again. In some cases, cooling may befacilitated using fans and/or other cooling mechanisms.

As seen in FIG. 12, after cooling, last member 102 may be removed frombraided footwear component 500 and exterior layer 104. In someembodiments, braided footwear component 500 and exterior layer 104 havebeen joined together to form a composite structure 650. Moreover,composite structure 650 may take the form of a footwear upper.

The term “composite structure” as used throughout this detaileddescription and in the claims refers to a structure comprised of two ormore materials. In the exemplary embodiment, the composite structure isconfigured as a plurality of tensile strands arranged in a braidedconfiguration (i.e., a braided footwear component), where the strandsare at least partially fixed to a heat deformable material (e.g., athermoplastic). The composite structure may have material propertiescorresponding to both the heat deformable material and the embeddedtensile strands. Thus, the heat deformable material, when cooled below aglass-transition temperature (or melting temperature), may act as abonding agent (e.g., a resin, matrix and/or adhesive) that at leastpartially coats the tensile strands and limits their relative movement.In particular, the composite structure may provide a more rigidstructure than the braided footwear component alone.

For purposes of clarity, the material comprising exterior layer 104,after being joined with braided footwear component 500 and cooled to asolid, may be referred to as a matrix portion of a composite structure.Moreover, the material comprising the matrix portion may be referred toas a matrix material. By joining the strands of a braided footwearcomponent with a matrix portion the strands may be partially fixed inplace, thereby reducing the tendency of the strands to becomedisorganized and/or reducing the tendency of the original braidingpattern to degrade over time. This matrix portion may also impartimproved wear resistance, strength, support and even cushioning(depending on the selected matrix material). In some cases, joining thebraided footwear component with a matrix portion may also help reduceunwanted stretch in a braided footwear component. Still further, thematrix portion (e.g., a thermoplastic) may fill in spaces betweenstrands to reduce the tendency of dirt and/or debris from entering thearticle through the upper. In other words, in some cases, a matrixportion may act as a sealant to the open mesh structure of a braidedfootwear component.

Some embodiments may further include steps of bonding sole elements tocomposite structure 650. In FIG. 13, an exemplary embodiment includes afirst sole component 700 and a second sole component 702, which havebonded to composite structure 650 in order to form a finished article offootwear 670. Sole components could incorporate one or more soleelements, including insole elements, midsole elements and/or outsoleelements. Moreover, sole components could be joined to a compositestructure (e.g., an upper) using adhesives, stitching, welding or anyother methods known in the art for joining uppers and soles.

In FIG. 13, composite structure 650 is seen to be comprised of strands550 (of a braided footwear component) that are joined with a matrixportion 652. As already discussed, matrix portion 652 is comprised ofmaterial (e.g., thermoplastic material) that previously formed exteriorlayer 104 of last system 100 (see FIG. 1). In this case, matrix portion652 forms a matrix within which strands 550 may be partially (or fully)embedded.

FIG. 14 illustrates a schematic isometric view of article of footwear670 as worn on a foot 799 of a user. FIGS. 15-17 illustrate variouspossible configurations for a composite structure, as taken along acutting surface indicated in FIG. 14. As seen in FIG. 15, in someembodiments strands 550 may be exposed on an outer surface 672 ofarticle of footwear 670. In this case, strands 550 may be partially, butnot fully, embedded within matrix portion 652. Moreover, strands 550 maybe separated from foot 799 by an inner surface 653 of matrix portion652. Such a configuration may be achieved by cooling exterior layer 104before strands 550 have time to completely pass through exterior layer104. This configuration may help improve feel with foot 799 by limitingcontact between strands 550 and foot 799.

Alternatively, as shown in FIG. 16, strands 550 could be completelyencased within matrix portion 652, such that no portions of strands 550are exposed on either inner surface 653 or outer surface 655 of matrixportion 652. Such a configuration may be achieved by forming matrixportion 652 with a thickness 730 that is substantially greater than adiameter 740 of strands 550. This configuration could improve feel andreduce wear to strands 550, since strands 550 are protected from contactwith a foot and objects exterior to article of footwear 670.

In still another configuration, shown in FIG. 17, strands 550 may bepartially, but not fully, embedded within matrix portion 652. In thiscase, strands 550 may be exposed on inner surface 653 of matrix portion652, but may not be exposed on outer surface 655 of matrix portion 652.Such a configuration may be achieved by allowing time for strands 550 tocontract through the entire thickness of exterior layer 104 beforecooling exterior layer 104. This configuration could provide increasedwear resistance of strands 550 against contact with objects on outersurface 655 of matrix portion 652. Of course, in still otherembodiments, matrix portion 652 may be thin enough so that strands 550are exposed on both an interior surface and an outer surface of matrixportion 652.

Embodiments can include provisions to vary the material characteristicsof a composite structure for an article of footwear. In someembodiments, a last system can be configured with an exterior layerhaving regions or zones with different thicknesses. When bonded withstrands of a braided footwear component, the regions or zones ofdifferent thicknesses may thereby provide different materialcharacteristics across different zones of the article. These materialcharacteristics could include, but are not limited to: rigidity,hardness, stretch, flexibility, as well as possibly other materialcharacteristics. For example, a first region with a first thickness thatis greater than a second thickness of a second region could providegreater rigidity for the first region over the second region.

FIG. 18 illustrates a step in a process for forming a last system 800.Referring to FIG. 18, a last member 802 has been formed using additivemanufacturing device 900. At this point, an extrusion head 905 ofadditive manufacturing device 900 is forming an exterior layer 804 oflast system 800. More specifically, exterior layer 804 is formed with atoe region 810 and an adjacent vamp region 812. As seen in FIG. 18, toeregion 810 has been formed with a greater thickness than vamp region812. In other words, more material has been laid down onto last system802 in toe region 810 than in vamp region 812.

FIG. 19 illustrates a schematic view of an embodiment of last system 800produced by the additive manufacturing process shown in FIG. 18.Referring to FIG. 19, last system 800 includes a toe region 810 as wellas an ankle region 816. In this embodiment, both toe region 810 andankle region 816 have substantially greater thicknesses than theremaining regions of exterior layer 804. Specifically, toe region 810has a first thickness 830, ankle region 816 has a second thickness 832and the remaining portions of exterior layer 804 (e.g., vamp region 812)have a third thickness 834. In the exemplary configuration, firstthickness 830 is greater than third thickness 834. Additionally, secondthickness 832 is also greater than third thickness 834.

FIG. 20 illustrates an exemplary configuration of composite structure1000 that may be created by forming a braided footwear component 1002over last system 800 (see FIG. 19) and applying heat to bond exteriorlayer 804 with braided footwear component 1002. Additionally, compositestructure 1000 may be attached to sole components 1001 to form anarticle of footwear 1003. Referring to FIGS. 19 and 20, toe region 810of exterior layer 804 has been combined with strands 1004 of braidedfootwear component 1002 to form a thickened toe region 1010 forcomposite structure 1000. Likewise, ankle region 816 of exterior layer804 has been combined with strands 1004 of braided footwear component1002 to form a thickened ankle region 1012 for composite structure 1000.

As shown in FIG. 20, toe region 1010 has a first thickness 1020, ankleregion 1012 has a second thickness 1022 and the remaining regions ofcomposite structure 1000 (e.g., vamp region 1014) have a third thickness1024. Moreover, first thickness 1020 is greater than third thickness1024 and second thickness 1022 is greater than third thickness 1024.This arrangement may result in a more rigid configuration for toe region1010 and ankle region 1012 as compared to, for example, vamp region 1014and other regions of composite structure 1000.

FIGS. 21 and 22 illustrate schematic views of a close up of toe region1010 and some of vamp region 1014 of composite structure 1000 with afoot 1100 inserted inside an article of footwear including compositestructure 1000. FIG. 21 represents a state in which composite structure1000 is not subjected to any forces, while FIG. 22 represents a state inwhich forces have been applied to composite structure 1000.

In FIG. 22, a first force 1202 is applied at toe region 1010. Also, asecond force 1204 is applied at vamp region 1014. For purposes ofcomparing the material properties of toe region 1010 and vamp region1014, it is considered that in this case first force 1202 and secondforce 1204 are equivalent. Such a force profile could be achieved when aball strikes against both toe region 1010 and vamp region 1014 ofcomposite structure 1000 simultaneously.

As seen by comparing FIGS. 21 and 22, the relative rigidity of toeregion 1010 prevents toe region 1010 from being substantially deformedunder the application of first force 1202. In contrast, vamp region 1014is seen to deform under second force 1204 due to its relatively lowerrigidity. This configuration therefore allows for increased protectionfor the toes. In other words, in some cases, toe region 1010 mayfunction in a similar manner to a toe cap and/or a toe pad to protectthe toes. Although FIGS. 21 and 22 illustrate the relative rigidity oftoe region 1010 to vamp region 1014, it may be understood that ankleregion 1012 may likewise be configured to resist deformations in asimilar manner to toe region 1010. This configuration of ankle region1012 may allow ankle region 1012 to provide similar strength and supportto the ankle as toe region 1010 provides to the toes.

FIG. 23 illustrates several different zones or regions of varyingthickness for an exterior layer of a last system, which may result incorresponding variations in thickness for a composite structure builtfrom the exterior layer and a braided footwear component. Referring toFIG. 23, last system 1300 includes last member 1302 and exterior layer1304. In some embodiments, exterior layer 1304 may include a thickenedbottom sole region 1310, which may provide additional strength, supportand possibly cushioning beneath a foot (e.g., to a sole of the foot)when exterior layer 1304 is incorporated into an article of footwear. Insome embodiments, exterior layer 1304 may include a thickened heelregion 1312, which may provide additional strength, support and possiblycushioning to the heel of a foot when exterior layer 1304 isincorporated into an article of footwear.

The zones of varying thickness may not be limited to regions with largeareas. In some cases, zones of varying thickness could be formed invarious geometries, including elongated shapes (e.g., ridges, channels,etc.). For example, in some embodiments, exterior layer 1304 may includea thickened eyestay region 1314, which may facilitate improved strengthfor eyelets in an article incorporating exterior layer 1304. Inparticular, in some cases, eyelets could be formed as holes withineyestay region 1314 of exterior layer 1304 and could be furtherreinforced by strands of an associated braided footwear component.Eyestay region 1314 is seen in FIG. 23 to have a generally elongatedshape that bounds the perimeter of a fastening region 1315 of lastsystem 1300. In some embodiments, exterior layer 1304 may incorporatethickened ridge regions 1318 (or ridge portions), for example in toeregion 1321. These ridge regions 1318 may comprise bands or lines ofincreased thickness in exterior layer 1304. Such ridges could maintaintheir approximate shape during the process of forming a compositestructure, so that the ridges may provide ball control or otherfunctionality for a finished article of footwear.

Although the following embodiments of composite structures (includingexterior layers) are characterized by having various zones or regionsthat are thicker than the remaining portions of the structures, otherembodiments could incorporate regions of substantially less thicknessthan the remaining portions. For example, it is contemplated that inanother embodiment, a majority of a composite structure could have afirst thickness, while a region (e.g., a medial side region) could havea second thickness that is substantially less than the first thickness.Such regions of lesser thickness could facilitate increased feel orproprioception on some areas of a foot, since these regions may be lessrigid than the remainder of the upper and therefore provide more tactilesensation to a wearer.

It will be understood that other embodiments may use selectively appliedregions of a material on an outer surface of a last member. Inparticular, an exterior layer need not be applied over the entiresurface of a last member, and instead could be applied in selectedregions. As one example, embodiments could include an exterior layerwith separate (e.g., disjoint) regions near the toes, vamp, heel and/orankle. In such cases, only some portions or regions of a braidedcomponent may be joined with an exterior layer so that the resultingstructure may comprise separated composite regions. For example, anembodiment could include an upper having a composite region of braidedstrands embedded in a matrix portion in a toe region, but may only havebraided strands (i.e., no matrix portion) in a vamp region. Suchselective applications of heat deformable materials may provide regionsof variable rigidity for a resulting upper.

While various embodiments have been described, the description isintended to be exemplary, rather than limiting and it will be apparentto those of ordinary skill in the art that many more embodiments andimplementations are possible that are within the scope of theembodiments. Accordingly, the embodiments are not to be restrictedexcept in light of the attached claims and their equivalents. Also,various modifications and changes may be made within the scope of theattached claims.

What is claimed is:
 1. A method of making an upper for an article offootwear, comprising: providing a last member, the last member having anouter surface; forming an exterior layer of a heat deformable materialonto the outer surface of the last member; forming a braided footwearcomponent onto the exterior layer; heating the exterior layer so thatthe exterior layer is joined with the braided footwear component to forma composite structure; and removing the last member from the compositestructure.
 2. The method according to claim 1, wherein the last memberis more rigid than the exterior layer.
 3. The method according to claim1, wherein heating the exterior layer includes heating the exteriorlayer above a characteristic temperature, wherein the exterior layer isdeformable above the characteristic temperature.
 4. The method accordingto claim 3, wherein the characteristic temperature is a glass transitiontemperature of the material comprising the exterior layer.
 5. The methodaccording to claim 3, wherein the characteristic temperature is amelting temperature of the material comprising the exterior layer. 6.The method according to claim 1, wherein forming the braided footwearcomponent onto the exterior layer comprises inserting the last memberwith the exterior layer through a braiding device.
 7. A method of makingan upper for an article of footwear, comprising: providing a lastmember, the last member having an outer surface; forming a first regionof an exterior layer onto the outer surface of the last member, whereinthe first region has a first thickness and wherein the exterior layer iscomprised of a heat deformable material; forming a second region of theexterior layer onto the outer surface of the last member, wherein thesecond region has a second thickness that is different from the firstthickness; forming a braided footwear component onto the exterior layer;heating the exterior layer so that the exterior layer is joined with thebraided footwear component to form a composite structure; and removingthe last member from the composite structure.
 8. The method according toclaim 7, wherein the first region of the exterior layer is associatedwith a first composite region of the composite structure, wherein thesecond region of the exterior layer is associated with a secondcomposite region of the composite structure, wherein the first compositeregion has a first thickness, and wherein the second composite regionhas a second thickness that is different than the first thickness. 9.The method according to claim 8, wherein the first composite region isthicker than the second composite region.
 10. The method according toclaim 9, wherein the first composite region is more rigid than thesecond composite region.
 11. The method according to claim 7, whereinforming the first region of the exterior layer includes printing theheat deformable material onto the last member using an additivemanufacturing process.
 12. The method according to claim 11, whereinforming the second region of the exterior layer includes printing theheat deformable material onto the last member using the additivemanufacturing process.
 13. The method according to claim 7, whereinforming the braided footwear component onto the exterior layer includesinserting the last member with the exterior layer through a braidingdevice.